Case Study: German Automotive Manufacturer achieves 5% efficiency gain with AnyLogic simulation software

Automotive Production Process Optimization

German Automotive Manufacturer’s logistics engineers needed a flexible way to optimize a complex commercial van production line and intralogistics network, especially with a large-scale AGV rollout. Traditional spreadsheet-based analysis could not adequately handle the plant’s thousands of parts, many vehicle variants, shared pathways, and strict no-stoppage requirement, so they turned to AnyLogic for simulation-based planning.

AnyLogic implemented a simulation model using the Material Handling Library, DXF-based layout import, real data, and a modular design so the tool could be reused across plants and updated easily. The solution delivered detailed routing and utilization analytics, helped validate a multi-million-euro AGV project before purchase, reduced manual planning effort by about 90%, and produced an initial 5% efficiency gain with another 5% identified through automation.